Apparatus for producing core yarn for antistatic carpet

ABSTRACT

A method and apparatus for producing antistatic yarn is described. Textile yarn such as nylon is passed under tension through a cabling zone and a conductive yarn is cabled under tension around the textile yarn at a rate of from 0.1 to 2.0 turns per inch of textile yarn.

ited States Patent Horsey et a1.

APPARATUS FOR PRODUCING CORE YARN FOR ANTlSTATlC CARPET Inventors: Robert W. Horsey, 51 Kingsford Ct.,

Kanata, Ontario; Emil John Brychta, 330 John St. N., Arnprior, Ontario, both of Canada Filed: Mar. 1, 1973 Appl. No.: 337,233

US. Cl. 57/18 Int. Cl B65h 81/08 Field of Search 57/16, 17, 18, 73

References Cited UNITED STATES PATENTS Hugo 57/18 Dec. 24, 1974 1,826,713 10/1931 Arnold 57/18 2,129,956 9/1938 Pastor 1 57/18 2,220,006 10/1940 Walsh et a1. 57/18 2,242,376 S/1941 57/18 3,133,401 5/1964 Servage 57/18 Primary ExaminerJohn Petrakes [5 7 ABSTRACT A method and apparatus for producing antistatic yarn is described. Textile yarn such as nylon is passed under tension through a cabling zone and a conductive yarn is cabled under tension around the textile yarn at a rate of from 0.1 to 2.0 turns per inch of textile yarn.

4 Claims, 1 Drawing Figure APP This invention relates to the production of anti-static yarn. More particularly it relates to the production of 5 a textile yarn having a conductive yarn cabled thereon.

It is presently known in the art to combine a conductive yarn with a textile yarn such as nylon to reduce the static charge build-up on such yarns or on carpets made from such yams. The conductive yarn is twisted with the textile yarn or tufted in parallel therewith. Carpets wherein one out of approximately every eight or ten yarn ends is a nylon-conductive yarn combination generally have a low propensity for retaining static charges.

It has been found however that when textile yarn and conductive yarns are twisted together twist differences in the yarn thus treated show up in the carpet when placed next to uncombined yarn. These differences appear as streaks due to the slight difference in loop formation in tufted carpet between the twisted and untwisted yarns.

Conventional ply twisting of conductive yarn and textile yarn will alter the twist level of the textile yarn and thus cause it to appear different from adjacent unmodified yarn. When conductive yarn is tufted in parallel with textile yarn in a tufted carpet it tends to either be buried in the surrounding textile yarn which renders it ineffective as a static charge reducer or it lies on the surface of the carpet which is detrimental to the appearance of the carpet.

One conductive yarn which is used for this purpose is a yarn of spun staple fibres of nylon blended with staple fibres of steel and sold by Brunswick Corporation under the trade mark Brunslon.

By using the cabling apparatus and method of the present invention the conductive yarn is cabled onto the textile yarn without appreciably changing the degree of twist of the textile yarn. The problem of streaks in the carpet product is thus effectively eliminated. Furthermore since the number of turns of conductive yarn on the textile yarn such as nylon need only be in the range of from 0.1 to 2.0 turns per inch of textile yarn to provide effective static reducing properties the conductive yarn cannot be easily detected in the finished carpet product when the applicants method is used. Concentrations of conductive yarn much above 2.0 turns per inch may make the conductive yarn more visible in the finished carpet.

A further advantage of the present invention can be found in the production of the antistatic carpet yarn wherein one production step can be eliminated. When conductive yarn and textile yarn are twisted together as is the usual practice in the art, this twisting operation is a separate and additional operation. By means of the present invention however, the conductive yarn can be cabled around the textile yarn during any plying or winding operation which might be necessary for the manufacture of the textile yarn.

In the applicants invention the conductive yarn is cabled onto the textile yarn at relatively high speed. For example, the textile yarn is passed through the cabling apparatus at the rate of from 100 to 600 yards per minute and the conductive yarn package is rotated at a rate of from 2,000 to 6,000 rpm to feed sufficient conductive yarn to provide from 0.1 to 2.0 turns of conductive yarn per inch of textile yarn passing through the apparatus. It has been found that if the tension of the conductive yarn is not carefully controlled or if less than 0.1 turns per inch is cabled onto the textile yarn, the conductive yarn tends to separate from the textile yarn and show up as loose threads on the surface of the carpet. When appreciably more than 2.0 turns per inch of conductive yarn are cabled onto the textile yarn the colour difference of the cabled yarn may differ slightly from the other textile yarn tufted side by side with it in the carpet depending on the colour tone of the conductive yarn itself.

By cabling with the apparatus of the present invention conductive yarn can be uniformly cabled on to the fibre since the spindle and yarn speeds are relatively constant and the funnel shaped portion of the spindle which is described below provides a means of maintaining a constant and uniform tension on the conductive yarn as it passes from the rotating cone onto the advancing textile yarn. By cabling at controlled tension the conductive yarn is uniformly cabled and held on to the textile yarn.

In the case of the Brunslon conductive yarn it was found that the tension during cabling operations should not be greater than 35 grams since the Brunslon had a tendency to break at higher tension.

It is therefore an object of this invention to provide a high speed cabling apparatus for cabling a conductive yarn onto a textile yarn.

It is another object of this invention to provide an improved method for an antistatic textile yarn by cabling a conductive yarn thereon.

These objects are obtained by means of a method which comprises passing a substantially straight length of textile yarn under tension through a cabling zone and cabling a conductive yarn under tension around the textile yarn at a rate of from 0.1 to 2.0 turns of conductive yarn per inch of textile yarn.

These objects are also obtained by means of an apparatus which comprises:

a. a rotatable cabler shaft comprising a yarn package holder, a spindle mounted on the apex of said package holder and an axial bore through said cabler shaft and spindle for passing textile yarn therethrough;

b. a yarn guide mounted downstream of said cabler shaft and spindle and spaced therefrom;

c. a passage through said yarn guide coaxial with the axial bore of said cabler shaft and spindle for continuing the passage of said textile yarn;

d. said spindle comprising a cabler shaft engaging portion and a funnel portion downstream of the shaft engaging portion which includes an outer edge for directing a length of conductive yarn from a yarn package mounted on said yarn package holder to a length of textile yarn passing through the passage of said yarn guide and cabling on said length of textile yarn when said cabler shaft is rotated.

The accompanying drawing is a partially schematic side view in partial cross-section of one embodiment of the cabling apparatus of the present invention.

The cabler shaft 1 is secured to side mounting 2 by means of nut 3 and rotatable thereon by means of bearing in a manner well known in the art. Cabler shaft 1 has a reduced diameter at one end 10 for mounting a yarn package holder 4. The yam package holder 4 of this embodiment shown in cross-section has a cone shaped outer surface with a centre passage 5 therethrough for mounting yarn package holder 4 on to the reduced diameter portion 1a of the shaft. The base 6 of yarn package holder 4 rests on shoulder 7 defined between the reduced diameter portion la of shaft 1 and the enlarged or upstream end lb. A spindle 8 shown in cross-section is threadedly mounted on the outwardly threaded downstream end 9 of shaft 1. Spindle 8 comprises a funnel shaped portion 10 extending approximately 36 from the centre of axis of the spindle in the embodiment shown, however angles from 25 to 60 were found to be useful. A female threaded passage is axially positioned through the body of the spindle for threadedly securing said spindle on to the downstream end 9 of shaft 1. The spindle 8 also includes a lip 11 at the end of the body remote from funnel portion 10. The spindle well portion 12 defined by 1 l is designed for receiving the tip of yarn package holder 4 when spindle 8 is mounted on shaft 1. An axial bore 13 is defined throughout cabler shaft 1 and provides a yarn passage through the shaft which opens into the centre of the funnel portion 10 of spindle 8.

A mounting bracket 14 is secured to side mounting 15 by means of threaded bolts 16. Mounting bracket 14 comprises a lateral opening 17 at its upper end through which yarn guide mount 18 is slidably positioned. Guide mount 18 slides in opening 17 so that the distance between mount 18 and spindle 8 may be adjusted. Guide mount 18 is secured in position by means of set screw 17a. A cylindrical yarn guide 19 is secured to the downstream end of guide mount 18 by means of set screw 19a and a guide passage 20 is provided through the guide 19 and mount 18. Yam guide 19 has a ceramic coating on its inner lip for purposes to be described below. Guide mount 18 and guide passage 20 and shown in cross-section for purposes of illustration.

1n the attached partially schematic drawing the apparatus is mounted on the two side mountings 2 and 15. These mountings are supported on base 21. It can be noted that side mounting 15 has its own mounting base 22 which in turn is secured to base 21 by threaded bolts 23.

An electric motor 24 is also mounted on base 21 and includes a drive shaft 25 with driving wheel 26 which cooperate with drive wheel 27 on shaft 1 by means of belt assembly 28 for axially rotating shaft 1.

A textile yarn 29 such as nylon is passed from a spindle source (not shown) and passed through axial bore 13 of shaft 1 in the direction indicated by the arrow. Nylon yarn 29 is passed through shaft 1 and spindle 8 into yarn guide passage 20 and outwardly therefrom in the direction indicated by the downstream arrow. lt was found that a nylon yarn speed at the rate of 100 yards/minute or slightly less to 600 yards/minute gave good results. A preferred speed is 270 yards/minute. A package of conductive yarn 30 shown in cross-section is mounted on yarn package holder 4 and the leading end of the conductive yarn 31 is directed outwardly over the outer edge of the funnel portion 10 of spindle 8 and into guide passage 20.

When shaft 1 is rotated axially by means of electric motor 24 the conductive yarn 31 as it is led off cone 30 is also rotated so that it is ballooned outwardly by the centrifugal force and extends in an eliptical are approximately as shown in the attached drawing. Yam 31 is led over the outer edge of the funnel portion 10 of spindle 8 and twisted around the nylon yarn 29 which passes through the centre of the spindle. Shaft l is rotated at a rate to provide from 2,000 to 6,000 rpm for the conductive yarn 31 at the point where it meets the nylon yarn 29. The cabler shaft 1 is rotated at such a rate that the conductive yarn is twisted around the advancing nylon yarn at the rate of from 0.1 to 2.0 turns per inch of conductive yarn. A rotating speed of from 2,000 rpm to 5,000 rpm was found to give good results. A rotation rate of from 0.3 to 10 turns per inch is preferred.

It might be noted that the degree of tension of the nylon yarn is maintained relatively constant at its point of winding since it is positioned between the yarn guide 19 and the lip 10 of spindle 8. This degree of tension can be varied by adjusting the position of yarn guide mount 18 in mounting bracket 17. By means of such adjustment, the yarn guide is moved farther away from spindle 8. This degree of tension can be carried out by adjusting the position of yarn guide mount 18 in mounting bracket 17. If by means of such adjustment the yarn guide is moved farther away from spindle 8 the angle of the nylon yarn with respect to the guide 19 will be reduced. It was found however that if the tension on the Brunslon conductive yarn 31 exceeds 35 grams it is liable to break. The tension limits may vary with conductive yarns of other manufacture. On the other hand if tension is dropped much below about 20 grams it is liable to loosen and separate from the textile yarn when incorporated into a carpet.

EXAMPLE 1 A 1% lb. cone of Brunslon staple fiber conductive yarn was mounted on a cabler as described above. A 1,150 denier nylon carpet fibre was passed through the coaxial bore of the apparatus and thence to a takeup winder where it was doubled with another carpet fibre. The takeup was run at 275 yds/min and the cabler at 3,000 rpm to give degree of cabling of 0.3 tpi of Brunslon on the nylon carpet fiber. After further processing, the yarn was tufted into carpets where the antistatic component made up every eight end. After dyeing and finishing the carpets were adequately protected from static and were judged to be satisfactory in appearance. No streaks were evident due to the presence of the Brunslon. Static propensity was 3.1 KV using TEST Method 134-1969 set out by the American Association of Textile Colorists and Chemists.

EXAMPLE 2 A 1 lb cone of a 19 denier monofilament nylon antistatic fibre was mounted as in Example 1. A 2,300 denier nylon yarn was passed through the coaxial bore of the apparatus immediately subsequent to its passing through a crimping apparatus and thence to the crimper takeup winder. The takeup speed was 500 yds/min and the cabler speed was 5,000 rpm to give a degree of cabling of 0.36 tpi of antistatic fiber on the nylon yarn. The yarn was tufted into carpets at a spacing of every eight end. After dyeing and finishing these carpets were quite satisfactory in appearance and static performance. (3.3 KV using AATCC 134-1969).

EXAMPLE 3 A conductive yarn was produced using the same quantities as set out in Example 2 but Brunslon staple fiber antistatic yarn was substituted for the monofilament antistatic yarn. The carpet tufted with this conductive yarn also exhibited satisfactory appearance and antistatic performance.

We claim: t

1. An apparatus for producing an antistatic carpet yarn which comprises:

a. a rotatable cabler shaft including a yarn package holder, a spindle mounted on the apex of said package holder and an axial bore through said cabler shaft and spindle for passing textile yarn therethrough:

b. a yarn guide mounted downstream of said cabler shaft and spindle and spaced therefrom;

c. a passage through said yam guide coaxial with the axial bore of said cabler shaft and spindle for continuing the passage of said textile yarn;

(1. said spindle comprising a cabler shaft engaging portion and a funnel portion downstream of the shaft engaging portion which includes an outer edge for directing a length of conductive yarn from a yarn package mounted on said yarn package holder to a length of textile yarn passing through the passage of said yarn guide and cabling on said length of textile yarn when said cabler shaft is rotated. 2. An apparatus as claimed in claim 1 which includes a means for passing textile yarn through said cabler shaft, spindle and yarn guide at a rate of from yards/minute to 600 yards/minute.

3. An apparatus as claimed in claim 2 which includes a means for rotating said cabler shaft at a rate of from 2,000 rpm to 5,000 rpm.

4. An apparatus as claimed in claim 3 which includes a means for maintaining said conductive yarn under constant tension in the range of from 20 grams to 35 grams. 

1. An apparatus for producing an antistatic carpet yarn which comprises: a. a rotatable cabler shaft including a yarn package holder, a spindle mounted on the apex of said package holder and an axial bore through said cabler shaft and spindle for passing textile yarn therethrough: b. a yarn guide mounted downstream of said cabler shaft and spindle and spaced therefrom; c. a passage through said yarn guide coaxial with the axial bore of said cabler shaft and spindle for continuing the passage of said textile yarn; d. said spindle comprising a cabler shaft engaging portion and a funnel portion downstream of the shaft engaging portion which includes an outer edge for directing a length of conductive yarn from a yarn package mounted on said yarn package holder to a length of textile yarn passing through the passage of said yarn guide and cabling on said length of textile yarn when said cabler shaft is rotated.
 2. An apparatus as claimed in claim 1 which includes a means for passing textile yarn through said cabler shaft, spindle and yarn guide at a rate of from 100 yards/minute to 600 yards/minute.
 3. An apparatus as claimed in claim 2 which includes a means for rotating said cabler shaft at a rate of from 2,000 rpm to 5,000 rpm.
 4. An apparatus as claimed in clAim 3 which includes a means for maintaining said conductive yarn under constant tension in the range of from 20 grams to 35 grams. 